Modular construction system

ABSTRACT

A construction assembly for a prefabricated building, comprises horizontal elements and vertical elements as well as assembly elements. The horizontal, vertical and assembly elements are formed by a first panel forming one of the longitudinal faces, a second panel forming a structuring layer on the opposite longitudinal face, and an insulating layer disposed between the longitudinal faces. The thickness U of the vertical elements corresponds to the cross-section of the assembly elements, the length of the vertical elements is a multiple of U, and at least some of the assembly elements further comprise fluid pipes and/or electrical cabling.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a national phase entry under 35 U.S.C. § 371 of International Patent Application PCT/FR2019/052231, filed Sep. 24, 2019, designating the United States of America and published as International Patent Publication WO 2020/065198 A1 on Apr. 2, 2020, which claims the benefit under Article 8 of the Patent Cooperation Treaty to French Patent Application Serial No. 1858639, filed Sep. 24, 2018.

TECHNICAL FIELD

The present disclosure relates to the field of the modular construction of prefabricated buildings, and more particularly to a construction assembly comprising a network of posts and beams allowing the arrangement and maintenance of vertical and horizontal walls, and some of which also integrate means for the circulation of fluids. At least part of the walls consist of SIF-type panels (structural, insulated, finished). The cross-section of the beams is substantially equal to the cross-section of the SIF panels.

The present disclosure relates to the field of the construction of buildings [IPC/EPC E04B], and, in particular, of small-scale buildings such as individual houses, grouped housing, offices, schools and other collective facilities (nursery, community centers, etc.).

The present disclosure relates more particularly to the field of off-site building construction.

Such constructions reduce the time, the costs and the risks linked to the site and also have a positive impact on the environment by limiting the nuisances caused by the construction (noise, pollution, logistics).

The present disclosure also relates to the field of the construction of buildings with high energy and environmental performance, in particular, those meeting low consumption building standards (as defined, in particular, by standards RT-2012, RT 2020, Passivhaus). Such buildings are characterized primarily by low energy consumption obtained by optimizing thermal insulation, moisture and air tightness, ventilation and thermal inertia.

In the context of this patent, the terms below will be interpreted as follows:

-   -   Off-site construction: designates a construction method         consisting in constructing all or part of a building outside its         installation site, for example, in a workshop or a factory, as         opposed to traditional on-site construction, which consists in         transporting the various materials to erect the structure of the         building on its site.     -   Modular construction: construction carried out by assembling         elements (modules) that are prefabricated in the factory,         possibly allowing the reuse and serial replication of the         elements.     -   “3D” modular construction: modular construction made up of         volumes that are partially or totally prefabricated and         pre-assembled in the factory, then transported and installed on         site;     -   “2D” modular construction: modular construction made up of         surface elements or (panels: floors, walls, roofs, partitions)         that are prefabricated in the factory and assembled on site;     -   Construction in kit form: construction on site from elements         pre-cut in the factory.     -   Sandwich panel: panels made up of different layers.     -   SIP panels (“Structural Insulated Panel”): sandwich panels         comprising at least one structural layer and one insulating         layer;     -   SIF panels (“Structural Insulated Finished”): SIP-type sandwich         panels further including interior/exterior finishes;     -   Fluids (Circulation of/Management of): refers to the means         assigned to the management of non-solid elements of the building         (water, electricity, gas, air). Generally, fluids comprise         plumbing (supply, discharge of wastewater and rainwater),         heating and ventilation, distribution of energy sources (gas and         electricity).     -   Thermal inertia: capacity of materials to maintain their         temperature.     -   Phase shift: ability of materials to retard temperature         variations.     -   Hygrometry: quantity of water vapor in the air, ambient         humidity.

BACKGROUND

French patent FR2610655 is known, which describes a known solution of a metal frame characterized in that it is constituted with a minimum of vertical posts, that is: at least four, incorporated in the corners, associated with metal profiles embedding the base of the panels, while the upper part of the panels is reinforced by metal inserts bolted to specific parts allowing the fixing of the lower ends of the trusses supporting the roof. This metal frame can be completely dismantled, while being largely hidden in the sandwich panels, either during the manufacture of the latter, or during assembly (like the corner posts).

U.S. Pat. No. 6,931,803 is also known describing a solution consisting in using a post-beam structure. The solidity of the construction is ensured by the fixing of the posts and beams. The walls do not play a structuring role here and can therefore be freely formed from any type of panel, in particular, sandwich-type panels as described above. This document of the prior art thus describes a method for implementing panels by means of extruded plastic beams making it possible to connect the vertical and horizontal elements. However, this document does not disclose any teaching enabling a person skilled in the art to integrate the circulation of fluids.

Patent application WO2012021055A2 describes a system comprising a plurality of building elements characterized by a hollow bar as a connecting means for connecting pillar assemblies and an engagement means for connecting pillar and wall assemblies. The system further comprises a column for forming pillar assemblies and a wall panel for forming wall assemblies. A first beam supports a floor and a second beam supports ceiling assemblies that comprise a junction plate on a first end and a second end for engaging the engagement means. A flat panel that forms a floor in the building comprises a plurality of supports for receiving penetrant.

The solutions of the prior art using structural insulated panels have the drawback of weight, cost, size and difficulties in transporting these structures.

The main problem with these solutions known in the state of the art is the complexity of implementation on the site. These systems do not resolve, or only partially resolve, the technical complexity of fluid management and finishing, which requires several months of work once the building is out of water and out of air. They also require additional procedures, after the assembly of the superstructure, to install the finishing equipment.

BRIEF SUMMARY

To get around this problem, those skilled in the art can turn to 3D modular construction, which involves prefabricating finished volumes that can, if necessary, integrate the finishing and the circulation of fluids. This type of prefabricated construction is extremely limited by the geometric constraints imposed by transport from the factory to the installation site.

The object sought by the present disclosure is to manufacture high-performance houses at a lower cost and in less time by assembling prefabricated modules on site that integrate all the necessary elements (structural work, light work, finishing.).

For this, it is necessary to solve the following implementation problems:

-   -   Assembly/fixing of the modules     -   Fluid circulation     -   Rainwater runoff     -   Ventilation     -   Electricity (High Current/Low Current)     -   Water supply (hot cold/hot)     -   Wastewater disposal.

To this end, the present disclosure relates in its most general sense to a construction assembly for a prefabricated building comprising horizontal elements and vertical elements as well as assembly elements, characterized in that the horizontal, vertical and assembly elements are formed by a first panel forming one of the longitudinal faces, a second panel forming a structuring layer on the opposite longitudinal face, and an insulating material disposed between the longitudinal faces, the thickness U of the vertical elements corresponding to the cross-section of the assembly elements, the length of the vertical elements being a multiple of U, at least some of the assembly elements further comprising fluid pipes and/or electrical cabling.

Advantageously, at least some of the elements have male connectors inserted at regular intervals on the rim of the elements, and female connectors inserted symmetrically and facing the male connectors on the corresponding rims.

Preferably, the rim of the assembly elements is machined at each insertion point of a female connector to create a trench at the bottom of which the female connector is housed.

Advantageously, the trench is wider on the edge of the rim of the assembly element to facilitate the insertion of the male connector.

According to a variant, the lower structural part of the assembly elements is composed of a bracket reinforced by a metal profile of rectangular cross-section defining a pipe for the ventilation of the air.

Advantageously, orifices are drilled regularly along the inner faces of the profile.

Preferably, the orifices also pass through the structuring bracket.

The present disclosure also relates to a method of constructing a prefabricated building according to the aforementioned structure, characterized in that the following is carried out successively:

-   -   installing one or more horizontal modules to form a floor,     -   connecting a network of lower beams on all the side faces of the         horizontal module(s),     -   elevating the vertical walls by connecting a series of vertical         modules and posts on the upper face of the lower beams, and     -   placing a second network of horizontal beams to which horizontal         panels will ultimately be connected in order to compose the roof         or the upper level.

BRIEF DESCRIPTION OF THE DRAWINGS

The present disclosure will be better understood upon reading the following description with reference to the accompanying drawings, where:

FIG. 1 is an exploded perspective view of the construction principle by connecting panels using corner beams;

FIG. 2 is a second exploded perspective view illustrating a building constructed according to the construction principle;

FIG. 3 is a side cross-section showing the alignment of a corner beam, a horizontal SIF panel (roof), and a vertical SIF panel (wall);

FIG. 4 is a side cross-section illustrating a building whose dimensions are multiples of the cross-section of the modules;

FIG. 5 is a perspective view of a male-type metal connector and of a female-type metal connector for fixing the modules together;

FIG. 6 is a perspective view of a beam incorporating a series of invisible female-type metal connectors;

FIGS. 7a and 7b are side cross-sections of a beam configured to integrate fluids;

FIG. 8 is a perspective view of a beam configured to integrate fluids;

FIG. 9 is a cross-sectional view of a post configured to integrate fluids;

FIG. 10 is a perspective view of a corner piece located at the intersection of two upper beams;

FIG. 11 shows a first variant for the internal structure of the vertical sandwich panel (SIF) of the wall type;

FIG. 12 shows an outer belt of a vertical sandwich-type panel (wall);

FIG. 13 shows a perspective view of an SIF roof panel;

FIG. 14 shows a perspective view of a variant of the assembly by means of machined connectors; and

FIG. 15 shows a perspective view of a vertical panel/beam assembly by means of a twist-lock.

DETAILED DESCRIPTION

The general principle of the present disclosure involves constructing a building by assembling prefabricated 2D modules on the installation site, as shown in FIG. 1. The structure is thus made up of horizontal (such as floors, roofs, glass roofs, balconies) and vertical (such as walls, partitions, joinery) elements assembled together by means of posts, beams and corner pieces.

In order to raise the building, one or more horizontal modules are first installed to form a floor (1). A network of lower beams (2) is then connected to all the side faces of the horizontal module(s). The vertical walls are then raised by connecting a series of vertical modules (3) and posts on the upper face of the lower beams. Then a second network of horizontal beams (4) is placed to which horizontal panels (5) will ultimately be connected in order to compose the roof or the upper level. FIG. 2 shows that the walls and floors are composed at least in part of structural panels and can also integrate non-structural elements (e.g., windows). When they are in contact with the outside, the panels can be of the sandwich type and advantageously of the SIF type (structural, insulated, finished). FIG. 3 shows, in cross-section, a vertical SIF panel (6), a horizontal SIF panel (roof) (7) and a corner beam (8). The material used for the structuring layer (9) of the panels is of little importance for the understanding and implementation of the present disclosure. Preferably, this layer may consist of laminated wood, for example, CLT (“Cross-Laminated Timber”), LVL or Lamibois (trade name). Those skilled in the art could alternatively use other materials (concrete or composite panels).

The insulating layer (10) consists of any type of insulation (e.g.: wood wool, mineral wool, polystyrene). The interior finish can be the structural material left raw, or a topcoat, for example, plaster, paint, or PLACOPLATRE® (Trade name), not shown in the figure.

The exterior finish is arbitrary (wood cladding, fiber cement, sheet metal, plaster). The precise composition of each sandwich panel is adapted according to its function (floor, ceiling, roof, wall, interior partition) and the material chosen for the structuring layer. For example, as can be seen in FIGS. 1, 2 and 3, the panels forming the roof comprise an outer face with a slight slope to allow the evacuation of rainwater. However, it should be remembered that, although having different compositions, the sandwich panels are designed so that their total thickness is substantially equivalent to the cross-section of the beam (denoted U in FIG. 3).

In addition, this feature optionally makes it possible to unify the dimensions of the different modules (FIG. 4). Indeed, using a standardized dimensional system based on multiples of the unit U (for example, U=40 cm) offers a considerable advantage to those skilled in the art, insofar as modules can be produced in series that are subsequently used in a wide variety of different projects.

The panels and the beams can be fixed together using techniques known to those skilled in the art (screws, dowels, glues). However, to facilitate and accelerate the on-site assembly of the building, a preferred assembly method involves using male and female connectors.

FIG. 5 illustrates an example of a male (11)-female (12) connector. The male connectors are inserted at regular intervals on the rim of the various panels, while the female connectors are inserted symmetrically and facing the male connectors on the corresponding rims of the beams (FIG. 6). The connectors can be aligned or staggered. To guide the male connector and make the beam-panel connection invisible, the rim of the beam is machined at each insertion point of a female connector to create a trench (13) at the bottom of which the female connector (14) is housed. Advantageously, the trench is substantially wider on the edge of the rim of the beam to facilitate the insertion of the male connector.

One of the problems that the present disclosure seeks to solve being the management of fluids, the internal structure of the posts and beams is used to circulate the electrical network, the ventilation and the evacuation of rainwater. Thus, while playing a structuring and insulating role, the posts and beams serve as a technical box for arranging the passage of fluids. FIGS. 7a and 7b illustrate one embodiment of the beams. The beams here are made up of two parts. The lower structural part (15) is composed of a bracket (16) (for example, glulam) reinforced by a metal profile (17) of rectangular cross-section. The profile acts both as an angle iron and as a duct for air ventilation. For this, orifices are drilled regularly (ideally at an interval equal to the unit U) along the internal faces of the profile. These orifices (21) also pass through the structuring bracket, as can be seen in the perspective view of the beam (FIG. 8). Along the profile, a raceway (18) is fitted to pass the electrical network (high current, low current, coaxial cables, Ethernet, fibers, etc.). The upper part of the beam (19) incorporates the insulation and is terminated by a channel (molded or extruded) allowing the evacuation of rainwater that flows from the roof panels. A waterproof membrane (for example, made from EPDM) covering the channel and overlapping the adjacent roof panel by several centimeters ensures the waterproofing of the whole.

The structure of the posts (FIG. 9) is comparable to that of the beams. It also contains a structural part, an insulator (30), a profile (31) for ventilation and a raceway (32) for carrying the electrical network and a channel (33) for the water pipes. The connection between the beams and the posts is made by means of a corner piece (35) shown in FIG. 10.

VARIANT EMBODIMENTS

FIG. 11 shows a first variant for the internal structure of the wall-type vertical sandwich panel (SIF) in the form of a load-bearing panel made up of cross-laminated timbers (CLT) providing the load-bearing function of the wall as well as its bracing and its interior finish. The outer face (41) of the CLT is covered (insulating side) possibly with a vapor barrier membrane. Vertical posts (42) and/or horizontal joists (43) hold the insulation (45) and secure the exterior cladding (44). The rainscreen film (46) is disposed on the outer face of the insulation. Cleats maintain an air gap (47) between the cladding and the rainscreen film.

Alternatively, vertical posts are braced by a wood particle board panel (e.g., OSB). The panel is lined with an internal partition, for example, by means of plasterboard mounted on aluminum profiles. A vapor barrier membrane is fixed to the inside of the panel.

According to another embodiment, the inner face (41) is composed of two wooden panels (for example, 3-ply or CLT) separated by cleats providing an empty space for the passage of the electrical ducts (52).

FIG. 12 shows an outer belt of a vertical-type sandwich panel (wall). The belt (51) consists of composite wood boards (e.g., LVL) coated on their outer face with a waterproofing membrane (e.g., EPDM). Recesses are made in the belt for the passage of the CMV (53) and electrical ducts (52).

Dovetail-type connectors (55) on the side rims (54) allow the vertical modules to be fixed together, whether they are wall-type SIF panels, corner posts, or modules incorporating joinery. The other fixing techniques described herein can also be applied.

Roof Element

FIG. 13 shows a perspective view of an SIF roofing panel made of composite wood beams (CLT or LVL) (61), insulating material (62) and two structural wood panels (CLT, or 3-ply) (63). For hot areas, the particle board (OSB) (65) is insulated with one layer of sound absorptive material (64) and covered with a waterproofing membrane (e.g.: EPDM).

The floor panels have a similar structure. The dry mineral floor consists of two boards of FERMACELL® (high-density gypsum) (65) and a layer of sound-absorptive material (64).

A honeycomb structure filled with sand (62) is alternated with composite wood beams (CLT or LVL).

Water and air tightness at the junction between two modules (for example, a wall and a beam) is ensured by the EPDM coating. The seal can be reinforced by means of a compressible sealing gasket (COMPRIBAND®) placed under the EPDM of one of the modules, combined with a recess on the module facing it.

Assembly by Machined Connectors

FIG. 14 shows a perspective view of a variant of the assembly by means of machined connectors for the connection of the horizontal modules to one another. Instead of the metal connectors, a structural composite wood board (for example, lamibois) is used, cut longitudinally to form two half-boards, denoted A and B.

The half-board (71) is fixed on the belt of a horizontal SIF panel (floor or ceiling); the half-board (72) is in turn fixed facing it on the beam. During assembly, the initial composite wood board is reconstituted.

To hold the panel-beam assembly horizontally and thereby replace the metal connectors, the board (71, 72) is cut in a repeating pattern that functions as a series of tenon-mortise connections. The pattern can be a series of slots or triangles, sawtooths, dovetails, etc. An almost sinusoidal pattern is particularly well suited because it facilitates the positioning and the interlocking of the modules.

The lower half-board (71) can receive recesses for the passage of ventilation and electricity ducts.

Connectors

FIG. 15 shows a perspective view of a vertical panel/beam assembly by means of a twist-lock. Twist connectors are commonly used in container transport. The connector known under the name of “twist-lock” consists of a female part (81) fixed or machined directly on the modules and a removable male connector (82) that is inserted between two modules.

The pattern is repeated periodically. Here, the repetition respects the U frame. 

1. A construction assembly for a prefabricated building, comprising: horizontal elements and vertical elements as well as assembly elements, wherein the horizontal, vertical and assembly elements are formed by a first panel forming a longitudinal face, a second panel forming a structuring layer on the opposite longitudinal face, and an insulating material disposed between the longitudinal faces, a thickness U of the vertical elements corresponding to a cross-section of the assembly elements, the length of the vertical elements being a multiple of U, and at least some of the assembly elements further comprising fluid pipes and/or electrical cabling.
 2. The assembly of claim 1, wherein at least some of the elements have male connectors inserted at regular intervals on a rim of the elements, and female connectors inserted symmetrically and facing the male connectors on the corresponding rims.
 3. The assembly of claim 2, wherein the rim of the assembly elements is machined at each insertion point of a female connector to create a trench at the bottom of which the female connector is housed.
 4. The assembly of claim 3, wherein the trench is wider on the edge of the rim of the assembly element to facilitate the insertion of the male connector.
 5. The assembly of claim 1, wherein a lower structural part of the assembly elements comprises a bracket reinforced by a metal profile of rectangular cross-section defining a pipe for ventilation of air.
 6. The assembly of claim 5, further comprising orifices formed regularly along inner faces of the profile.
 7. The assembly of claim 6, wherein the orifices pass through the bracket.
 8. A method constructing a prefabricated building, comprising the following steps carried out successively: installing one or more horizontal modules to form a floor, connecting a network of lower beams on all side faces of at least one horizontal module, elevating vertical walls by connecting a series of vertical modules and posts on an upper face of the lower beams, placing a second network of horizontal beams to which horizontal panels will ultimately be connected in order to compose a roof or an upper level. 